pp-d013 - apas

PP-D013

PAINTING CONTRACTOR CERTIFICATION PROGRAM ACCREDITATION REQUIREMENTS – CLASSES 1 TO 4

PCCP D013 V8 Authorised by Executive Officer, PCCP of 12 Date of issue 11/05/2020 © Copyright CSIRO 2020

Editorial Note: This version of the document added Class 1 - Shop application – enclosed facilities for immersion service.

1. SCOPE

a) This document establishes the accreditation requirements for contractors involved in the Protective Coatings Category, Classes 2 to 4 Shop and/or Site application of protective coatings to steel, concrete and other structures.

b) It needs to be noted that PCCP is a trademark registered with IP Australia and is owned by CSIRO and is protected by applicable laws. Unauthorised use is prohibited.

2. INTRODUCTION

a) For details of the PCCP scheme, its history, management and operation, refer to PCCP Documents D001 to D004.

b) For details on the various protective coating accreditation Categories, Classes and Sub-classes, refer to PCCP Document D007.

3. AUTHORITY AND RESPONSIBILITY

a) The Executive Officer, PCCP (EO) is responsible for the content of the procedure and has the authority to implement the requirements of this procedure.

4. REFERENCED DOCUMENTS

This procedure refers to the following PCCP documents:

1. Document PP-D001 How PCCP Operates. 2. Document PP-D002 Quality Policy 3. Document PP-D003 Schedule of fees 4. Document PP-D004 Complaint handling 5. Document PP-D007 Categories and Classes 6. Document PP-D008 SHREQ management system

criteria 7. Form PP-F002 – Initial application for PCCP

accreditation

All PCCP documents and forms are available for downloading from the Documents section of the PCCP web site at: http://www.apas.gov.au/

Spray Painting and Powder Coating Code of Practice available at: https://www.safeworkaustralia.gov.au/doc/model-code-practice-spray-painting-and-powder-coating

5. DEFINITIONS AND ACRONYMS 5.1 Acronyms

ABN Australian Business Number ACN Australian Company Number CSIRO Commonwealth Scientific and Industrial

Research Organisation EO Executive Officer, PCCP ITP Inspection and Test Plan

KPI Key Performance Indicator NCR Non-conformance report PCCP Painting Contractor Certification Program RPL Recognition of Prior Learning SHREQ Safety Health, Regulatory, Environmental and

Quality (management systems) SWMS Safe Work Method Statement

5.2 Definitions

Applicant – an organisation applying for accreditation under the PCCP Scheme. The Applicant can be a company or trading entity with (in Australia) a valid ABN or ACN.

Traditional Dry Abrasive Blasting – normal air-assisted, abrasive blasting using any form of dry, angular media such as garnet, steel shot, carbide or alumina.

Abrasive Blasting Code of Practice – available at: https://www.safeworkaustralia.gov.au/doc/model-code-practice-abrasive-blasting

6. CLASSES AND SUB-CLASSES

a) Accreditation against the Protective Coatings category can be in the following classes, as described in PP-D007:

i) Class 1: Painting shop application for immersion service.

ii) Class 2: Painting shop application for atmospheric service.

iii) Class 3: Site application of coatings for atmospheric service.

iv) Class 4: Site application of coatings for immersion service.

b) In addition, accreditation against the Protective Coatings category can also be in the following sub-classes:

i) Sub-class 1: Traditional protective coatings – solvent borne, water borne, powder coatings, high solids, solvent free etc, organic or inorganic.

ii) Sub-class 2: Thermal metal spray. iii) Sub-class 3: Intumescent coatings – thin film

single pack solvent borne acrylics or single pack water borne products, or thick film two pack epoxies.

c) Requirements for each are set out in clause 7 below.

d) Designations are in the format Class 2-1, 3-3 etc.

http://www.apas.gov.au/

https://www.safeworkaustralia.gov.au/doc/model-code-practice-spray-painting-and-powder-coating

https://www.safeworkaustralia.gov.au/doc/model-code-practice-spray-painting-and-powder-coating

https://www.safeworkaustralia.gov.au/doc/model-code-practice-abrasive-blasting

https://www.safeworkaustralia.gov.au/doc/model-code-practice-abrasive-blasting

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ACCREDITATION REQUIREMENTS – CLASSES 1 TO 4


7. ACCREDITATION REQUIREMENTS 7.1 General

a) In order to become an accredited contractor, the Applicant must be able to provide evidence that the following three major elements are routine parts of their normal business:

i) A working SHREQ management system complying with the requirements detailed in PCCP document PP-D008 is in place and being regularly used to drive the business.

ii) Technical capability and specialist processes relevant to the application of coatings are in place and being regularly used to drive the business. Refer PP-D008 clause 7.

iii) Specialist equipment necessary to carry out activities to the satisfaction of the client, are available and being regularly used to drive the business. Refer clause 9 below.

b) The Applicant also needs to be able to show that throughout the organisation, at all levels, there is a commitment to Quality principles, a desire to improve the business using those principles, and a knowledge of the organisation's position on quality. Senior management is expected to be intimately involved in the process via:

i) Regular management review of results (KPI, NCR, complaints), trends.

ii) The provision of adequate resources (human, skills, equipment etc) to enable policies, goals and objectives to be achieved.

7.2 Specific Requirements – Classes 1 and 2

7.2.1. General a) These Classes cover the surface preparation and

application of coatings in-house, such as in enclosed abrasive blasting and spray-painting facilities owned by the Applicant Contractor.

b) The Applicant needs to be able to show that it has the specialist equipment requirements detailed in Clause 9 below.

c) The Applicant needs to be able to demonstrate a client base and a history of successfully undertaking a range of jobs appropriate to the Class of accreditation sought.

7.2.2. Classes 1-1 and 2-1 Specific Requirements: Shop Application of Liquid and Powder Coatings a) Where traditional dry abrasive blasting is utilised,

the facility needs to:

i) Be fully enclosed – four (4) fixed, hard walls and a roof. The space can be part of a larger enclosed multi-purpose area provided that 7.2.2 a) iii) and v) below are satisfied.

ii) Be capable of producing the standard of surface preparation nominated in the specification or tender documents or client requirements (profile and grade of blasting). This means having access to appropriate grades of blasting media which will deliver the desired level of quality of preparation.

iii) Contain blast residues so that environmental pollution (air, soil) of the surrounding area is avoided.

iv) Have a means of capturing and collecting waste blast media and a system for disposal and/or recycling.

v) Have in place sufficient engineering controls to ensure appropriate quality of air supply, such as oil and water traps and worker protection, such as via air extraction.

vi) Comply with the requirements in the Abrasive Blasting Code of Practice and all applicable local regulations. The onus is on the contractor to ascertain what these local requirements are and to comply with them.

b) Other means of abrasive or non-abrasive blasting for surface preparation shall utilise appropriate engineering and procedural controls to ensure worker, public and environmental safety. As well as being capable of producing a standard of surface preparation (profile and grade of blast) nominated in the specification or tender documents or client requirements.

c) The spray-painting facility shall:

i) Be fully enclosed – four (4) fixed, hard walls and a roof plus a baking oven for powder coatings. The space can be part of a larger enclosed multi-purpose area provided that 7.2.2 c) iii) below is satisfied.

ii) Comply with the requirements in the Spray Painting and Powder Coating Code of Practice and all applicable local regulations. The onus is on the contractor to ascertain what these local requirements are and to comply with them.

iii) Have in place sufficient engineering controls to ensure appropriate quality of air supply, such as oil and water traps and worker protection, such as via air extraction and filtration.

d) Although it is preferable to have a dedicated spray booth with proper filtered extraction, a non-dedicated facility is permissible provided that appropriate engineering controls are in place to keep spray hands and other employees safe from the effects of overspray and eliminate cross-contamination between jobs.

7.2.3 Classes 1-2 and 2-2 Specific Requirements: Shop Application of Thermal Metal Spray

a) Surface preparation facilities for thermal metal spray shall comply with the requirements of clause 7.2.2 a) to b) inclusive.

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b) The application facility for thermal metal spray shall comply with 7.2.2 c) and d) above.

7.2.4 Class 2-3 Specific Requirements: Shop Application of Intumescent Coatings

a) Surface preparation facilities for intumescent coatings shall comply with the requirements of clause 7.2.1 a) to b) inclusive.

b) The application facility for intumescent coatings shall comply with 7.2.1 c) and d) above.

7.3 Specific Requirements – Classes 3 and 4

7.3.1 General a) This Class covers the surface preparation and

application of coatings on site, such as abrasive blasting and spray-painting facilities at the Applicant Contractor’s client’s site.

b) Classes 3 and 4 have identical specialist requirements (documents, equipment etc) with the following exceptions:

i) For Class 4 (immersion service), applicator skills with specialist products will need to be demonstrated: • Via Certificate of Attendance at a product

manufacturer’s training course. • Via Recognition of Prior Learning (RPL).

ii) For Class 4 (immersion service), holiday testing becomes mandatory.

c) Classes 3 and 4 apply to the application of coatings from the following sub-classes as defined in PP-D007:

i) Sub-class 1: Liquid organic or inorganic coatings.

ii) Sub-class 2: Thermal metal spray coatings. iii) Sub-class 3: Intumescent coatings (not Class

4).

d) The Applicant needs to be able to show that it has the specialist equipment requirements detailed in Clause 9 below.

c) The Applicant needs to be able to demonstrate a client base and a history of successfully undertaking a range of jobs appropriate to the Class of accreditation sought.

7.3.2 Class 3-1 Specific Requirements: Site Application of Liquid Coatings

a) Engineering controls over site surface preparation and application of coatings depend on:

i) The nature and size of the asset being coated. ii) The nature of the coating being removed, and

the coating being applied. iii) The location of the asset and what other assets

are nearby. iv) Client specification requirements.

b) Surface preparation activities shall be controlled via a documented SWMS that details each step in the process and the controls to be exercised over the activity whilst considering 7.3.2 a) above.

c) Coating application activities shall be controlled via a documented SWMS that details each step in the process and the controls to be exercised over the activity whilst considering 7.3.2 a) above.

d) Witness, Inspection, Hold and Test Points for the whole process shall be documented in a detailed ITP. Records of release shall be kept.

e) The level of documented control (SWMS, ITP) shall be appropriate for the size, complexity, importance and risk profile of the job being undertaken.

7.3.3 Class 3-2 Specific Requirements: Site Application of Thermal Metal Spray

a) The surface preparation for, and application of, thermal metal spray coatings shall comply with 7.3.2 above.

7.3.4 Class 3-3 Specific Requirements: Site Application of Intumescent Coatings

a) The surface preparation for, and application of, intumescent coatings shall comply with 7.3.2 above.

b) Spray application of these coatings shall be performed by operators with skills, knowledge and experience in, and appropriate to, intumescent coatings, demonstrated: i) Via Certificate of Attendance at a product

manufacturer’s training course. ii) Via Recognition of Prior Learning (RPL).

7.3.5 Class 4-1 Specific Requirements: Site Application of Liquid Coatings for Immersion Service

a) The requirements for this Class shall be as per clause 7.3.2 above.

7.3.6 Class 4-2 Specific Requirements: Site Application of Thermal Metal Spray Coatings for Immersion Service

a) The requirements for this Class shall be as per clause 7.3.2 above.

8. APPLICATION PROCESS

The application process is detailed in PCCP Document PP-D001 clause 6.

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9. TECHNICAL CAPABILITY 9.1 Inspection and Test Equipment (ITE) and Standards

9.1.1 Liquid Organic, Inorganic and Powder Coatings

Classes 1 and 2 Shop Work

Classes 3 and 4 On Site Work

For Immersion Service

For Atmospheric

Service

For Atmospheric

Service For Immersion

Service

Designation 1-1 2-1 3-1 4-1

ITE Requirement AS 1627 Parts 1-9 (inc.) M M M M AS 3894 Method 1-4 (inc.) M M M M AS 3894 Method 10-12 (inc.) M M M M Profile Comparator / STD M M M M Abrasive Blast Visual STD M M M M Temperature - Surface M M M M Temperature - Ambient M M M M Temperature logger – powder oven M M

Relative Humidity reader M M M M Whirling Psychrometer M M M M Dew Point – Electronic M M M M Dew Point – Calculator M M M M Optical Magnifier (x10) O O O O Wet Film Thickness Gauge M M M M Dry Film Thickness: 0-1250µm M M M M 0-5000µm O O M M Set of Standards or Shims M M M M Continuity Tester: Low Voltage M O O M High Voltage M O O M Barcol 935 O O M M Durotest M M M M Pencil Hardness Set O O O O Lead Check O O O O Inspection Markers e.g. Chalk M M M M Adhesion Tester O O O O Masking Tape M M M M Stanley Knife / Scalpel M M M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired/leased/borrowed.

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9.1 Inspection and Test Equipment (ITE) and Standards (cont.,)

9.1.2 Thermal Metal Spray Coatings



For Immersion Service

For Atmospheric

Service

For Atmospheric


Service

Designation

1-2 2-2 3-2 4-2

ITE

Requirement

AS 1627 Parts 1-9 (inc.) M M M M AS2312 M M M M AS 3894 Method 1-4 (inc.) M M M M AS 3894 Method 10-12 (inc.) M M M M EN 22063 M M M M ISO 14918 M M M M ISO 14231 M M M M ISO 582 M M M M Qualify documentation -TMS M M M M Hydraulic adhesion tester and dollies M M M M

Metallographic testing (available to contractor) AR AR AR AR Chloride testing - Substrate M M M M Chloride testing - Abrasive M M M M Testex tape and profile gauge M M M M Bend tester and plates M M M M Profile Comparator / STD Abrasive Blast Visual STD M M M M Temperature - Surface M M M M Temperature - Ambient M M M M Relative Humidity gauge M M M M Whirling Psychrometer M M M M Optical Magnifier (x10) O O O O Set of Standards or Shims M M M M Continuity Tester: Low Voltage M O O M High Voltage M O O M Inspection Marker- French Chalk M M M M

Masking Tape M M M M Stanley Knife / Scalpel M M M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired / leased / borrowed. AR = As required.

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9.1 Inspection and Test Equipment (ITE) Standards (cont.,)

9.1.3 Intumescent Coatings



Not Intended for

Immersion Service

For Atmospheric

Service

For Atmospheric

Service Not Intended

for Immersion

Service Designation 2-3 3-3

ITE Requirement

AS 1627 Parts 1-9 (inc.) M M AS 3894 Method 1-4 (inc.) M M AS 3894 Method 10-12 (inc.) M M Profile Comparator/STD M M Abrasive Blast Visual STD M M Temperature - Surface M M Temperature - Ambient M M Relative Humidity reader M M Whirling Psychrometer M M Dew Point – Electronic M M Dew Point – Calculator M M Optical Magnifier (x10) O O Wet Film Thickness Gauge M M Dry Film Thickness: 0-1250µm M M 0-5000µm M M Set of Standards or Shims M M Lead Check O O Inspection Markers e.g. Chalk M M Adhesion Tester O O Masking Tape M M Stanley Knife / Scalpel M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired / leased / borrowed.

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9.2 Surface Preparation Equipment

9.2.1 Liquid Organic, Inorganic and Powder Coatings



For Immersion

Service For

Atmospheric Service

For Atmospheric


Service


Equipment Requirement

Compressor Brand / Type: Capacity:

M M M M

Bull Hose / Major airline from compressor M M M M

Blast Helmet(s) M M M M Abrasive Blast Hopper M M M M Blast Hose-Anti-static M M M M Blast Nozzle M M M M Nozzle Orifice Gauge M M M M Needle Nozzle Pressure Gauge M M M M Oil/Water Separators M M M M Aftercooler (Tropical Application) M M M M Dehumidifier O O O O Blast Room: Fixed [ ] Mobile [ ] M M M M

Dust Extractor / Cleaning M M O O Brass Hammer / Tools M M M M Abrasive Storage Hoppers / Bins M M M M Abrasive Handling Equipment M M M M Angle Grinder M M M M Disk Sander M M O M Orbital Sander M M O M Wire brush (Hand) M M M M Wire brush (Rotary) M M M M Needle Gun 1.5 mm O O O O Needle Gun 3.0 mm O O O O Air Receiver / Drier M M M M Air Supply (Filter) to Blast Helmet M M O O Mobile Equipped / Transportable O O M M Waste Disposal Facility M M M M Abrasive Recovery Unit M M M M Lighting - Blast Room M M M M Safety Clothing / Spectacles M M M M First Aid / Eye Wash Bottles M M M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired/leased/borrowed.

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9.2 Surface Preparation Equipment (cont.,)




For

Immersion Service

For Atmospheric

Service

For Atmospheric

Service

For Immersion

Service




M M M M

Bull Hose / Major airline from compressor M M M M

Blast Helmet(s) M M M M Abrasive Blast Hopper M M M M Blast Hose-Anti-static M M M M Blast Nozzle M M M M Nozzle Orifice Gauge M M M M Needle Nozzle Pressure Gauge M M M M Oil/Water Separators M M M M Aftercooler M M M M Dust Extractor / Cleaning O M O O Brass Hammer / Tools O O O O Abrasive Storage Hoppers / Bins M M M M Abrasive Handling Equipment O O O O Angle Grinder M M M M Disk Sander O O O O Orbital Sander O O O O Wire brush hand M M M M Wire brush rotary M M M M Needle Gun 1.5 mm O O O O Needle Gun 3.0 mm O O O O Air Receiver / Drier M M M M Air Supply (Filter) to Blast Helmet M M M M Mobile Equipped / Transportable O O M M Waste Disposal Facility M M M M Abrasive Recovery Unit M M M M Lighting - Blast Room M M M M Safety Clothing / Spectacles M M M M First Aid / Eye Wash Bottles M M M M Bristle Blaster tool O O O O HP water blast / cleaning – 3000 psi min M M M M

Biodegradable degreaser and dispenser M M M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired/leased/borrowed

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9.2 Surface Preparation Equipment (cont.,)



Class 3 and 4 On Site Work

Not Intended for

Immersion Service

For Atmospheric

Service

For Atmospheric

Service Not Intended

for Immersion

Service

Designation

2-3 3-3



M M

Bull Hose / Major airline from compressor

M M

Blast Helmet(s) M M Abrasive Blast Hopper M M Blast Hose-Anti-static M M Blast Nozzle M M Nozzle Orifice Gauge M M Needle Nozzle Pressure Gauge M M Oil/Water Separators M M Aftercooler (Tropical Application) M M Dehumidifier O O Blast Room: Fixed [ ] Mobile [ ]

M M

Dust Extractor / Cleaning O O Brass Hammer / Tools M M Abrasive Storage Hoppers / Bins M M Abrasive Handling Equipment M M Angle Grinder M M Disk Sander O O Orbital Sander O O Wire brush hand M M Wire brush rotary M M Needle Gun 1.5 mm O O Needle Gun 3.0 mm O O Air Receiver / Drier M M Air Supply (Filter) to Blast Helmet O O Mobile Equipped / Transportable M M Waste Disposal Facility M M Abrasive Recovery Unit M M Lighting - Blast Room M M Safety Clothing / Spectacles M M First Aid / Eye Wash Bottles M M


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9.3 Application Equipment

9.3.1 Liquid Organic and Inorganic Coatings

Class 1 and 2 Shop Work


For Immersion

Service For

Atmospheric Service

For Atmospheric


Service



Conventional Spray Gun M M M M Airless Spray Gun M M M M Powder Spray Gun: powder coat M Pressure Pot: Agitated [ ] Non Agitated [ ] M M M M

Airless Pump: ≤ 30:1 Ratio O O O O >30:1 Ratio O M O O Plural Head Airless Spray Gun M O M M Conventional Material Hose M M M M High Pressure Material Hose M M M M Air Hose M M M M Pressure Gauge: Pot M M M M Atomising Air M M M M Airless Pump M M M M Oil / Water Sep.: Gun M M M M Compressor M M M M Dehumidifier O O O O Paint Rollers M M M M Brushes M M M M Covered Paint Store M M M M Gantry Crane O O O O Mobile Crane O O O O Trestles M M M M Nylon Slings O M O O Wire Slings M O M M Chain Slings M M M M Vacuum Cleaner M M M M Vacuum Surface Prep. Tools M M M M Respirators M M M M Flame Proof Lighting M M M M Exhaust Conduits / Flexible M O M M Air Blowers: Hot / Cold M O M M High Pressure Water Washers M M M M Scaffold M M M M Ladder M O M M Undercover Paint Bay M M O O Yard Storage Capacity M M O O Degreasing Bay O O O O

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired / leased / borrowed

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9.3 Application Equipment (cont.,)




For

Immersion Service

For Atmospheric

Service

For Atmospheric

Service

For Immersion

Service

Designation

1-2

2-2

3-2

4-2


High Pressure Material Hose O O O O Air supply hose M M M M TMS wire storage area M M M M Gantry Crane O O O O Mobile Crane O O O O Trestles M M M M Nylon Slings O M O O Wire Slings M O M M Chain Slings M M M M Vacuum Cleaner M M M M Respirators – metallic particle M M M M Operator Spray helmet with tinted visor

M M M M

Tinted safety glasses M M M M Fire extinguisher M M M M Flame Proof Lighting O O O O Exhaust Conduits / Flexible M O M M Air Blowers Cold M O M M Scaffold M M M M Ladder M O M M Yard Storage Capacity M M Degreasing Bay O O O O Thermal metal spray application unit-Arc spray system M M M M

TMS application unit including gas(es) – Flame spray system AR AR AR AR

Wire cutters / pliers M M M M Wire lubrication M M M M Electrical leads - 3 phase IP65 M O M M Generator diesel DC / 3 phase M O M M Air compressor diesel – min 100 cfm (for Metal spray air supply) M M M M

Note 1: M = Mandatory that equipment is owned. O = Optional that equipment can be hired / leased / borrowed. AR = As required.

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9.3 Application Equipment (cont.,)



Class 3 and 4 On Site Work

Not Intended

for Immersion

Service

For Atmospheric

Service

For Atmospheric

Service

Not Intended

for Immersion

Service

Designation

2-3

3-3


Airless Spray Gun (17-23 thou tip) M M Pressure Pot Agitated [ ] Non Agitated [ ]

M M

Airless Pump >45:1 Ratio M M Conventional Material Hose M M High Pressure Material Hose M M Air Hose M M Pressure Gauge: Pot M M Airless Pump M M Oil/Water Sep. Gun M M Handheld air driven mixer (helical shaft)

M M

Dehumidifier O O Brushes M M Covered Paint Store M M Gantry Crane O O Mobile Crane O O Trestles M M Nylon Slings O O Wire Slings M M Chain Slings M M Vacuum Cleaner M M Respirators M M Flame Proof Lighting M M Exhaust Conduits / Flexible M M Air Blowers: Hot / Cold M M High Pressure Water Washers M M Scaffold M M Ladder M M Undercover Paint Bay M O Yard Storage Capacity M O Degreasing Bay M O
